Insulating concrete form

ABSTRACT

An insulating concrete form system for the construction of insulated concrete walls, floors or roofs, the system comprising: at least one first panel; at least one second panel configured to be placed opposite to the at least one first panel, and a plurality of spacers configured to interconnect the at least one first panel and the at least one second panel while defining a space between the at least one first panel and the at least one second panel. A method for constructing a concrete wall, floor or roof, as well as additional embodiments of the system and method, are provided herein.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application No. 62/522,381, filed Jun. 20, 2017, the entire contents of which is incorporated herein by reference in its entirety.

FIELD

The present subject matter relates to construction. More particularly, the present subject matter relates to industrialized construction of walls.

BACKGROUND

Insulating concrete form, as known as insulated concrete form, is a system of formwork for reinforced concrete usually made with a rigid thermal insulation that stays in place as a permanent interior and exterior substrate for walls, floors, and roofs. The forms are interlocking modular units that are dry-stacked, without mortar, and filled with concrete. The units lock together and create a form for the structural walls or floors of a building.

Insulating concrete forms are usually manufactured from insulating materials, for example, polystyrene foam, polyurethane foam, cement-bonded wood fiber, cement-bonded polystyrene beads, cellular concrete, and thastyron—a mixture of cement, water and recycled expanded polystyrene.

Reinforcing steel bars are usually placed inside the forms before concrete if poured to give the concrete flexural strength. After the concrete has cured, the forms are left in place permanently.

Nevertheless, the currently available insulating concrete forms have several drawbacks, for example they are prone to leakage of water at the outer surface of the insulating concrete form, especially at the border lines between adjacent insulating concrete forms; thermal insulator layers add extra weight to the insulating concrete forms; placement of reinforcing steel bars in the space where concrete is to be poured is cumbersome, and following construction of a wall with the currently available insulating concrete forms there is a need to plaster and/or paint the outer surfaces of the insulating concrete forms.

SUMMARY

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this subject matter belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present subject matter, suitable methods and materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

According to one aspect of the present subject matter, there is provided an insulating concrete form system for the construction of insulated concrete walls, floors or roofs, the system comprising:

-   -   at least one first panel;     -   at least one second panel configured to be placed opposite to         the at least one first panel, and     -   a plurality of spacers configured to interconnect the at least         one first panel and the at least one second panel while defining         a space between the at least one first panel and the at least         one second panel.

According to one embodiment, the space is configured to be filled with concrete.

According to another embodiment, the at least one first panel, the at least one second panel and the plurality of spacers are configured to be a part of the constructed wall, floor or roof.

According to yet another embodiment, the at least one first panel is configured to serve as a surface of a wall, floor or roof that faces an exterior of a building;

-   -   the at least one second panel is configured to serve as a         surface of a wall, floor or roof that faces an interior of a         building, and     -   the plurality of spacers is configured to be embedded in         concrete.

According to still another embodiment, the at least one first panel, the at least one second panel and the plurality of spacers are fire resistant.

According to a further embodiment, the at least one first panel, the at least one second panel and the plurality of spacers are configured to serve as thermal insulators.

According to yet a further embodiment, the at least one first panel, the at least one second panel and the plurality of spacers are configured to serve as acoustic insulators.

According to still a further embodiment, the at least one first panel, the at least one second panel and the plurality of spacers are made of recycled plastic, wood powder, and adhesives.

According to an additional embodiment, either the first panel, or the second panel, or the first panel and the second panel, comprise:

-   -   a first panel surface and     -   a second panel surface,     -   enclosing at least one hollow compartment.

According to yet an additional embodiment, the hollow compartment is filled with an insulating material.

According to still an additional embodiment, the insulating material is a thermal insulating material.

According to an additional embodiment, the insulating material is an acoustic insulating material.

According to a further embodiment, the insulating material is air.

According to one embodiment, the first panel and the second panel, comprise:

a female connector at one side, and

a male connector at an opposite side,

wherein the male connector of a first panel is configured to engage with a female connector of an adjacent first panel, and the male connector of a second panel is configured to engage with a female connector of an adjacent second panel positioned underneath it.

According to a further embodiment, the two adjacent first panels are positioned one above the other, and the two adjacent second panels are positioned one above the other.

According to yet a further embodiment, the spacer comprises at least one recess.

According to still a further embodiment, the recess is positioned at an upper part of the spacer when the spacer is assembled together with the at least one first panel and the at least one second panel.

According to another embodiment, the recess is configured to bear a reinforcing bar.

According to another aspect of the present subject matter, there is provided a method for constructing a concrete wall, floor or roof, the method comprising:

-   -   placing at least one first panel opposite to an at least one         second panel;     -   interconnecting the at least one first panel and the at least         one second panel with a plurality of spacers, while defining a         space between the at least one first panel and the at least one         second panel, and     -   pouring concrete into the space.

According to one embodiment, while placing the at least one first panel opposite to an at least one second panel, a male connector of one first panel is engaged with a female connector of an adjacent first panel, and a male connector of one second panel is engaged with a female connector of an adjacent second panel.

According to another embodiment, the two adjacent first panels are positioned one above the other, and the two adjacent second panels are positioned one above the other.

According to yet another embodiment, before pouring concrete into the space, the method further comprises:

-   -   placing reinforcing bars onto the spacers.

According to still another embodiment, the spacer comprises at least one recess.

According to a further embodiment, the recess is positioned at an upper part of each spacer when the spacers interconnect the at least one first panel and the at least one second panel.

According to yet a further embodiment, before pouring concrete into the space, the method further comprises:

placing of reinforcing bars onto the recesses of the spacers.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the embodiments. In this regard, no attempt is made to show structural details in more detail than is necessary for a fundamental understanding, the description taken with the drawings making apparent to those skilled in the art how several forms may be embodied in practice.

In the drawings:

FIG. 1 schematically illustrates, according to an exemplary embodiment, a perspective view of an assembled insulating concrete form system.

FIG. 2 schematically illustrates, according to an exemplary embodiment, a cross-side view of a first panel.

FIG. 3 schematically illustrates, according to an exemplary embodiment, a cross-side view of a lower first panel assembled with an upper first panel.

FIG. 4 schematically illustrates, according to an exemplary embodiment, a perspective side view of an assembled insulating concrete form system comprising two first panels and assembled one above the other, and two second panels and assembled one above the other, interconnected with a plurality of spacers.

FIG. 5 schematically illustrates, according to an exemplary embodiment, a perspective side view of an assembled insulating concrete form system a first panel and a second panel interconnected by a plurality of spacers.

FIG. 6 schematically illustrates, according to an exemplary embodiment, a side view of an assembled insulating concrete form system a first panel and a second panel interconnected by a plurality of spacers.

FIG. 7 schematically illustrates, according to an exemplary embodiment, a front view of a panel, for example a first panel, from a side looking at a surface of the first panel that faces the space in an assembled insulating concrete form system, where concrete is to be poured, for example the second panel surface.

FIG. 8 schematically illustrates, according to an exemplary embodiment, a side view of an opening accessory.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before explaining at least one embodiment in detail, it is to be understood that the subject matter is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The subject matter is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. In discussion of the various figures described herein below, like numbers refer to like parts. The drawings are generally not to scale.

An aim of the present subject matter is to provide an insulating concrete form that eliminates the aforementioned drawbacks of the currently available insulating concrete forms.

According to one aspect of the present subject matter there is provided an insulating concrete form system for the construction of insulated concrete walls, floors or roofs.

FIG. 1 schematically illustrates, according to an exemplary embodiment, a perspective view of an assembled insulating concrete form system 1, comprising: at least one first panel 10, at least one second panel 20 configured to be placed opposite to the at least one first panel and a plurality of spacers 30 configured to interconnect the at least one first panel 10 and the at least one second panel 20 while defining a space 40 between the at least one first panel 10 and the at least one second panel 20. The space 40 is configured to be filled with concrete. According to one embodiment, after pouring of the concrete in the space 40, the at least one first panel 10, the at least one second panel 20 and the plurality of spacers 30 are configured to remain as parts of the constructed wall, floor or roof. According to another embodiment, the at least one first panel 10 is configured to serve as a surface of a wall, floor or roof that faces an exterior of a building, the at least one second panel 20 is configured to serve as a surface of a wall, floor or roof that faces an interior of a building, and the plurality of spacers 30 are configured to be embedded in concrete.

According to one embodiment, the at least one first panel 10, at least one second panel 20 and the plurality of spacers 30 are made of any material known in the art that is suitable for the preparation of insulating concrete forms. According to a preferred embodiment, the at least one first panel 10, at least one second panel 20 and the plurality of spacers 30 are made of recycled materials, for example but not limited to, recycled plastic and other polymers, wood powder, and adhesives—thus rendering the insulating concrete form system 1 beneficial in terms of environmental preservation and ecological aspects.

FIG. 2 schematically illustrates, according to an exemplary embodiment, a cross-side view of a first panel 10. The embodiments illustrated in FIG. 2 are relevant to either the first panel 10, or the second panel 20, or the first panel 10 and the second panel 20. According to this embodiment, the first panel 10 may comprise a first panel surface 110 and a second panel surface 120 enclosing at least one hollow compartment 130. Similarly, the second panel 10 may comprise a first panel surface and a second panel surface enclosing at least one hollow compartment.

Each hollow compartment 130 is filled with an insulating material. According to one embodiment, the insulating material is a thermal insulating material, for example air, foam, and the like. According to another embodiment, the insulating material is an acoustic insulating material, for example an acoustic insolating fiber, insulating wool and the like. According to a preferred embodiment, the hollow compartment 130 is filled with air. As a result, the at least one first panel 10 and the at least one second panel 20 have an intrinsic insulating capacity. Therefore, according to one embodiment, there is no need to add an insulating material to the insulating concrete form system 1. A person skilled in the art may well appreciate the advantage of this embodiment over currently available insulating concrete forms.

According to one embodiment, the first panel 10, illustrated in FIG. 2, and the second panel 20, comprise a female connector 140 at one side, and a male connector 150 at an opposite side. The male connector 150 of one first panel 10 is configured to engage with a female connector 140 of an adjacent first panel 10, whereas the male connector of a second panel is configured to engage with a female connector of an adjacent second panel. According to another embodiment, the two adjacent first panels 10 and the two adjacent second panels 20 are positioned one aside the other. According to a preferred embodiment, the two adjacent first panels 10 and the two adjacent second panels 20 are positioned one above the other.

FIG. 3 schematically illustrates, according to an exemplary embodiment, a cross-side view of a lower first panel 10-I assembled with an upper first panel 10-II. Similar embodiments are relevant also to the second panel 20. According to one embodiment, the male connector 150-II of the upper first panel 10-II is engaged with the female connector 140-I of the lower first panel 10-I. The shapes of the female connector 140 fits the shape of the male connector 150, thus enabling precise fit of the female connector 140 and the male connector 150. Similar embodiments are relevant also to the female connector 240 and the male connector 250 of the second panel 20 (not shown).

Returning now to FIG. 2, according to one embodiment, the female connector 140 comprises a downwardly diagonal part 145, and the male connector 150 comprises a corresponding diagonal part 155 that fits with the shape of the downwardly diagonal part 145 of the female connector 140 during assembly of adjacent first panels 10. The downwardly diagonal part 145 and the corresponding diagonal part 155 are preferably positioned at the edge of the first panel surface 110, preferably in an embodiment when the first panel surface 110 faces an exterior of a building.

Returning now to FIG. 3, it can be seen that the diagonal part 155-II of the upper first panel 10-II engages with the downwardly diagonal part 145-I of the lower first panel 10-I. This particular fitness eliminates leakage of water through the border line between a lower first panel 10-I and an upper first panel 10-II, particularly in embodiments where the first panel surface 110 of the 10 panel faces an exterior of a building. Thus, due to the downwardly diagonal part 145 and the corresponding diagonal part 155, leakage of rain water is eliminated because in order to leak the water has to move upwards over the downwardly diagonal part 145.

FIG. 4 schematically illustrates, according to an exemplary embodiment, a perspective side view of an assembled insulating concrete form system 1 comprising two first panels 10-I and 10-II assembled one above the other, and two second panels 20-I and 20-II assembled one above the other, interconnected with a plurality of spacers 30. According to the embodiment illustrated in FIG. 4, a lower first panel 10-I is assembled with an upper first panel 10-II, a lower second panel 20-I is assembled with an upper second panel 20-II, and a plurality of spacers 30 interconnect the first panels 10-I and 10-II and the second panel 20-I and 20-II. Furthermore, according to the embodiment illustrated in FIG. 4, the lower first panel 10-I comprises a male connector 150-I that engages with a male connector 140-II of the upper first panel 10-II. Similarly, the lower second panel 20-I comprises a male connector 250-I that engages with a male connector 240-II of the upper second panel 20-II. As may be appreciated, the female connector 140 and 240 and the male connector 150 and 250 may be either at an upper edge or a lower edge of the first panel 10 or second panel 20.

According to the embodiment illustrated in FIG. 4, the female connector 140 and 240 does not comprise a downwardly diagonal part 145, and the male connector 150 and 250 does not comprise a corresponding diagonal part 155.

FIG. 5 schematically illustrates, according to an exemplary embodiment, a perspective side view of an assembled insulating concrete form system 1, comprising a first panel 10 and a second panel 20 interconnected by a plurality of spacers 30.

FIG. 6 schematically illustrates, according to an exemplary embodiment, a side view of an assembled insulating concrete form system 1, comprising a first panel 10 and a second panel 20 interconnected by a plurality of spacers 30.

According to the embodiment illustrated in FIGS. 5 and 6, a spacer 30 comprises at least one recess 35, preferably positioned at an upper part of the spacer 30 when the spacer 30 is assembled together with the at least one first panel 10 and the at least one second panel 20. According to one embodiment, the recess 35 of the spacer 30 is configured to bear a reinforcing bar placed in the space 40 before pouring concrete into the space 40. The reinforcing bar may be made for example of steel. The recesses 35 of the spacers allow easy and convenient placement of the reinforcing bars, while eliminating undesired movement of the reinforcing bars during assembly of the insulating concrete form system 1. A person skilled in the art may well recognize the advantage of this embodiment over currently available insulating concrete forms not having spacers 30 comprising recesses 35 for bearing reinforcing bars.

FIG. 7 schematically illustrates, according to an exemplary embodiment, a front view of a panel, for example a first panel 10, from a side looking at a surface of the first panel that faces the space 40 in an assembled insulating concrete form system 1, where concrete is to be poured, for example the second panel surface 120. According to one embodiment, the surface of the first panel 10 and the second panel 20 that faces the space 40 comprises a plurality of hooking holes 80 dispersed over the surface. The hooking holes 80 are configured to hook spacers 30 during the assembly of the insulating concrete form system 1.

According to one embodiment, the hooking hole 80 comprises a wide portion 82 and a slot 84. During assembly of the insulating concrete form system 1, an edge of a spacer 30 is inserted into the wide portion 82 of the hooking hole 80, and then pushed into the slot 84 in a manner that fixes the spacer 30 in place. This embodiment allows easy and convenient placement of the spacers 40 during the assembly of the insulating concrete form system 1.

FIG. 8 schematically illustrates, according to an exemplary embodiment, a side view of an opening accessory 60. According to one embodiment, the opening accessory 60 is configured to be assembled with the insulating concrete form system 1 in places where there is to be an opening in the wall, for example a door opening, a window opening and the like. The opening accessory 60 prevents from concrete to enter into a part of the space 40 where there is to be an opening.

According to one embodiment, the components of the insulating concrete form system 1 may have any dimension according to desired construction needs. Thus, the insulating concrete form system 1 of the present subject matter is suitable for construction of any size of walls, floors and roofs.

According to one embodiment, the length of the first panel 10 and the second panel 20 may be any desired length. According to another embodiment, the length of the first panel 10 and the second panel 20 is up to substantially 12 meters.

According to one embodiment, the height of the first panel 10 and the second panel 20 may be any desired height. According to another embodiment, the height of the first panel 10 and the second panel 20 is in the range of substantially 10-60 centimeters.

According to one embodiment, the width of the first panel 10 and the second panel may be any desired height. According to another embodiment, the width of the first panel surface 110 and 220 is substantially 6 millimeters, the width of the second panel surface 120 is substantially 6 millimeters, and the width of hollow compartment 130 is substantially 12 millimeters, giving rise to a total width of the first panel 10 and the second panel 20 of substantially 24 millimeters.

According to one embodiment, the length of the spacer 30 defines the width of the space 40, and as a result it also defines the width of the concrete portion of a wall, floor or roof that is constructed with the insulating concrete form system 1. The spacer 30 may have any desired length, for example but not limited to, 15 centimeters.

According to one embodiment, after assembling the insulating concrete form system 1, and pouring of the concrete, the first panel 10 and the second panel 20 remain attached to the concrete and become part of the constructed wall, floor or roof. Since the first panel 10 and the second panel 20 are part of the wall, floor or roof, the surfaces of the first panel 10 and the second panel 20 that face the exterior or interior of a building may be manufactured in any desired form, texture and color, for example but not limited to, stone-like, wood-like, skim coat-like, and the like. Manufacturing of the first panel 10 and the second panel 20 with a desired form, texture and color eliminates further manipulation of a constructed wall, floor and roof, like plastering and painting, after completing the pouring of concrete. According to an additional embodiment, the surfaces of the first panel 10 and the second panel 20 that face the exterior or interior of a building may be manufactured blank, thus allowing plastering and/or painting of the surfaces after pouring of the concrete.

According to one embodiment, the components of the insulating concrete form system 1, namely the at least one first panel 10, the at least one second panel 20 and the plurality of spacers 30, stand in all international construction standards. In addition, the component of the system 1 are fire resistant, configured to serve as thermal insulators, and configured to serve as acoustic insulators. According to a preferred embodiment, the components of the system 1 have a high thermal insulation level and a high acoustic insulation level. Furthermore, a building constructed with the insulating concrete form system 1 of the present subject matter withstands earthquakes since the first panel 10 and the second panel 20, interconnected with the spacers 30, envelop and strengthen the concrete and eliminate its disintegration during earthquakes for example.

According to one embodiment, usage of the insulating concrete form system 1 of the present subject matter eliminates the involvement during construction of professionals like plasterers, painters, molders and the like, thus reducing construction costs and time.

According to one embodiment, since the components of the insulating concrete form system 1 of the present subject matter are made of recycled materials, the system 1 is rendered ecologically environment-friendly, namely promoting green construction.

According to another aspect of the present subject matter there is provided a method for constructing a concrete wall, floor or roof, the method comprising:

placing at least one first panel 10 opposite to an at least one second panel 20;

interconnecting the at least one first panel 20 and the at least one second panel 20 with a plurality of spacers 30, while defining a space 40 between the at least one first panel 10 and the at least one second panel 20, and

pouring concrete into the space 40.

According to one embodiment, while placing the at least one first panel 10 opposite to an at least one second panel 20, a male connector of one first panel 10 is engaged with a female connector of an adjacent first panel 10, and a male connector of one second panel 20 is engaged with a female connector of an adjacent second panel 20.

According to another embodiment, the two adjacent first panels 10 are positioned one above the other, and the two adjacent second panels 20 are positioned one above the other.

According to a further embodiment, before pouring concrete into the space 40, the method for constructing a concrete wall, floor or roof further comprises:

placing reinforcing bars onto the spacers 30.

According to yet a further embodiment, the spacer 30 comprises at least one recess. According to yet a further embodiment, the recess is positioned at an upper part of each spacer 30 when the spacers 30 interconnect the at least one first panel 10 and the at least one second panel 20.

According to an additional embodiment, before pouring concrete into the space 40, the method for constructing a concrete wall, floor or roof further comprises:

placing of reinforcing bars onto the recesses of the spacers.

It is appreciated that certain features of the subject matter, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the subject matter, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub combination.

Although the subject matter has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. 

1. An insulating concrete form system for the construction of insulated concrete walls, floors or roofs, the system comprising: at least one first panel; at least one second panel configured to be placed opposite to the at least one first panel, and a plurality of spacers configured to interconnect the at least one first panel and the at least one second panel while defining a space between the at least one first panel and the at least one second panel.
 2. The system of claim 1, wherein the space is configured to be filled with concrete.
 3. The system of claim 1, wherein the at least one first panel, the at least one second panel and the plurality of spacers are configured to be a part of the constructed wall, floor or roof.
 4. The system of claim 1, wherein the at least one first panel is configured to serve as a surface of a wall, floor or roof that faces an exterior of a building; the at least one second panel is configured to serve as a surface of a wall, floor or roof that faces an interior of a building, and the plurality of spacers is configured to be embedded in concrete.
 5. (canceled)
 6. The system of claim 1, wherein the at least one first panel, the at least one second panel and the plurality of spacers are configured to serve as thermal insulators.
 7. (canceled)
 8. The system of claim 1, wherein the at least one first panel, the at least one second panel and the plurality of spacers are made of recycled plastic, wood powder, and adhesives.
 9. The system of claim 1, wherein either the first panel, or the second panel, or the first panel and the second panel, comprise: a first panel surface and a second panel surface, enclosing at least one hollow compartment.
 10. The system of claim 9, wherein the hollow compartment is filled with an insulating material. 11-13. (canceled)
 14. The system of claim 1, wherein the first panel and the second panel, comprise: a female connector at one side, and a male connector at an opposite side, wherein the male connector of a first panel is configured to engage with a female connector of an adjacent first panel, and the male connector of a second panel is configured to engage with a female connector of an adjacent second panel positioned underneath it.
 15. The system of claim 14, wherein the two adjacent first panels are positioned one above the other, and the two adjacent second panels are positioned one above the other.
 16. The system of claim 1, wherein the spacer comprises at least one recess.
 17. The system of claim 16, wherein the recess is positioned at an upper part of the spacer when the spacer is assembled together with the at least one first panel and the at least one second panel.
 18. The system of claim 16, wherein the recess is configured to bear a reinforcing bar.
 19. A method for constructing a concrete wall, floor or roof, the method comprising: placing at least one first panel opposite to an at least one second panel; interconnecting the at least one first panel and the at least one second panel with a plurality of spacers, while defining a space between the at least one first panel and the at least one second panel, and pouring concrete into the space.
 20. The method of claim 19, wherein while placing the at least one first panel opposite to an at least one second panel, a male connector of one first panel is engaged with a female connector of an adjacent first panel, and a male connector of one second panel is engaged with a female connector of an adjacent second panel.
 21. The method of claim 20, wherein the two adjacent first panels are positioned one above the other, and the two adjacent second panels are positioned one above the other.
 22. The method of claim 19, wherein before pouring concrete into the space, the method further comprises: placing reinforcing bars onto the spacers.
 23. The method of claim 19, wherein the spacer comprises at least one recess.
 24. The method of claim 23, wherein the recess is positioned at an upper part of each spacer when the spacers interconnect the at least one first panel and the at least one second panel.
 25. The method of claim 24, wherein before pouring concrete into the space, the method further comprises: placing of reinforcing bars onto the recesses of the spacers. 